6MT Conversion Project

[kday]

But just to be clear, you need to swap the ABS unit *and* tune the ECU to clear the CELs?

[RAUDI]

But just to be clear, you need to swap the ABS unit *and* tune the ECU to clear the CELs?

Yes. You need both.

You need the ECU tuning.

You need to swap the ABS unit. (or you can do the electronic side if you don't want to mess with the wet side as was mentioned by ttboost a few posts ago) There are 2 options for the ABS that Steveken told me should work. 4B0614517AA or 4B0614517E

[RAUDI]

I got the majority of my timing bearing and pulleys in the mail yesterday. (Europaparts missed one of my relay rollers, but shipped it out when I called them.)

I started with the hydraulic tensioner and that went fine. Then I went to put in the new thermostat and I broke off one of the bolts into the block. I gave up on that piece of crap click style torque wrench and immediately went to Sears to get a bar type. Hopefully my Snap-On clicker will be back from service soon. I was able to use the dremel to cut a groove in the bolt, put the screwdriver in it with pliers attached, then a friend tapped it with a hammer while I turned it. Got it out with no additional damage. Thank goodness.

[alrightroad]

I got the majority of my timing bearing and pulleys in the mail yesterday. (Europaparts missed one of my relay rollers, but shipped it out when I called them.)

I started with the hydraulic tensioner and that went fine. Then I went to put in the new thermostat and I broke off one of the bolts into the block. I gave up on that piece of crap click style torque wrench and immediately went to Sears to get a bar type. Hopefully my Snap-On clicker will be back from service soon. I was able to use the dremel to cut a groove in the bolt, put the screwdriver in it with pliers attached, then a friend tapped it with a hammer while I turned it. Got it out with no additional damage. Thank goodness.

nice work!

[RAUDI]

nice work!

Thank you. All in all I was as happy as I could be. It may have been a pain in the rear and added hours to the simple task, but luckily I am in no hurry and it was not as bad as it could have been.

[RAUDI]

Here is a picture of all of the timing belt parts and the front of the block all cleaned up with them installed. (sans relay rollers and belt until tomorrow)


I replaced 2 of the obvious cam seals. Are the other 2 the ones with the black caps?


Pulled the toothed belt sprocket and replace the crank seal as well. I had to use a screwdriver to get the seal puller into this one. I was careful not to damage anything. Reinstalling to the bolt that holds the sprocket in was crazy. Specs call for a new one. I didn't do that. It goes to 200nm and then another 180 degrees. I only got about 100 degrees before I felt like I was going to break something. My 1/2" breaker bar in the picture was very visibly bending. I stopped at that point.


The other relay will be here tomorrow. I will be finishing up the TB job and wiring up the new "custom" bullet connectors for the knock sensors to replace the heat damaged stock clips. Then it's on to wiring the brakes/reverse and installing the shifter. Soon I'll be out of things to do until I get more moolah. Speaking of that, I placed my deposit with Steveken yesterday. I am very excited.

[Bigglezworth]

I think you need a cleaner 10 yr old vehicle to work on..... Egad. Has that car even seen rain?

[P1054]

Yes. You need both.

You need the ECU tuning.

You need to swap the ABS unit. (or you can do the electronic side if you don't want to mess with the wet side as was mentioned by ttboost a few posts ago) There are 2 options for the ABS that Steveken told me should work. 4B0614517AA or 4B0614517E

On the ABS unit subject: those two part numbers are for which cars? One is the W8 Passat, what is the other? Also, how much does the module (complete with both dry and wet side) cost? I'm curious because I think mine may have an issue (the ABS and ESP lights come on intermittently, the code says "open or short to +" on the rear right wheel speed sensor but the sensor is still good). If it is part of the 6-speed swap, that's just one more reason on an ever-growing list for me to pull the trigger on the project!

Fantastic work by the way, both with the project and the documentation here! Keep it up, and good luck going forward!

[hahnmgh63]

Maybe one of the guys who have done the swap will sell you their old ABS unit or at least the dry side?

[RAUDI]

Maybe one of the guys who have done the swap will sell you their old ABS unit or at least the dry side?

I may know someone with a very clean one..... oh. ME! :-)

[Korben007]

I'm about to start tearing apart my RS6. Already got an S6 ABS setup. Car has 60k. ABS works great. Will be for sale.

[RAUDI]

On the ABS unit subject: those two part numbers are for which cars? One is the W8 Passat, what is the other? Also, how much does the module (complete with both dry and wet side) cost? I'm curious because I think mine may have an issue (the ABS and ESP lights come on intermittently, the code says "open or short to +" on the rear right wheel speed sensor but the sensor is still good). If it is part of the 6-speed swap, that's just one more reason on an ever-growing list for me to pull the trigger on the project!

Fantastic work by the way, both with the project and the documentation here! Keep it up, and good luck going forward!

I believe the other one comes from the C5 S6. I feel like I got a great deal at $160 shipped. I think they generally go for over $200. Also, you should now have access to the Google Drive. Let me know if you have things to add.

[RAUDI]

Got the timing finished up today. Getting the cams lined up with the bar was kind of a chore, but I got it after a few minutes. Here it is with everything and then the covers. There isn't a picture of it, but I installed the dampener also. It went in at 22nm, tightened in a star fashion, with blue loctite. I've been using torque specs and blue on everything, but I'm especially worried after Beardown's experience. Wish me luck.


Changed out the fuel filter and a couple of the hose clamps. The fastener that holds the pump in place is an M8 triple square. Everything on this car seems so well planned out, except the random fastener choices. Its like they rolled a die for each piece and sometime a wildcard allowed a throw for every hole. My ratchet came out from under the car all clean and new after a nice bath in 93 octane.


Also changed out the air filter and cleaned the air box. I took a picture of how filthy it was for you, Biggelzworth.

[Chase]

Here is a picture of all of the timing belt parts and the front of the block all cleaned up with them installed. (sans relay rollers and belt until tomorrow)


I replaced 2 of the obvious cam seals. Are the other 2 the ones with the black caps?


Pulled the toothed belt sprocket and replace the crank seal as well. I had to use a screwdriver to get the seal puller into this one. I was careful not to damage anything. Reinstalling to the bolt that holds the sprocket in was crazy. Specs call for a new one. I didn't do that. It goes to 200nm and then another 180 degrees. I only got about 100 degrees before I felt like I was going to break something. My 1/2" breaker bar in the picture was very visibly bending. I stopped at that point.


The other relay will be here tomorrow. I will be finishing up the TB job and wiring up the new "custom" bullet connectors for the knock sensors to replace the heat damaged stock clips. Then it's on to wiring the brakes/reverse and installing the shifter. Soon I'll be out of things to do until I get more moolah. Speaking of that, I placed my deposit with Steveken yesterday. I am very excited.

You should really really replace that torque-to-yield bolt and get the 180 degree turn on it. And use a 3/4" or 1" breaker bar. Makes it easier.

[Beardown1]

Omg.....just look at the carbon deposits on the butterfly.......your a pig!!!!

[RAUDI]

You should really really replace that torque-to-yield bolt and get the 180 degree turn on it. And use a 3/4" or 1" breaker bar. Makes it easier.

I will look into getting one today, before I get anymore of it together.

[RAUDI]

You should really really replace that torque-to-yield bolt and get the 180 degree turn on it. And use a 3/4" or 1" breaker bar. Makes it easier.

OK.....I ordered it for $12.95. Ridiculous. There was a silver lining. When looking at the site I noticed they had one set of these mounts left for $150! I got them. So thanks for being my quality assurance officer, Chase. I shouldn't have been skimping in the crank/timing area anyways.

http://www.europaparts.com/034motors...rsport-v8.html

[RAUDI]

Omg.....just look at the carbon deposits on the butterfly.......your a pig!!!!

Good eye, smartarskie. ;-) You know that really was bothering me! I am planning to do an intake de-carb kit when it's back on the road.